Alkoxylation processes and catalysts therefor

ABSTRACT

A process of contacting an alkylene oxide with 2-methoxy-1-propanol (PM1) in the presence of an oligomeric Schiff base metal complex catalyst is disclosed. Further, a process involving contacting an alkylene oxide with an alkyl alcohol using an oligomeric Schiff base metal complex as a catalyst is also disclosed. Additionally, novel compositions which can be used as catalysts in processes involving the contacting of an alkyl alcohol with an alkylene oxide are also disclosed.

FIELD OF THE INVENTION

This invention relates to novel Schiff base compositions. This invention further relates to contacting an alkylene oxide with an alcohol in the presence of a Schiff base catalyst. This invention also relates to the propoxylation of 2-methoxy-1-propanol and 1-methoxy-2-propanol.

BACKGROUND OF THE INVENTION

The conversion of propylene oxide using base-catalyzed conditions to produce a mixture of monopropylene glycol methyl ethers (PM), dipropylene glycol methyl ether (DPM), tripropylene glycol methyl ethers (TPM) and heavier molecular weight polypropylene glycol methyl ethers is the current industry standard technology for commercial PM glycol ethers. The mixture of the mono-, di-, tri- and heavier product categories can be controlled by adjusting the methanol-to-propylene oxide feed mole ratio, recycling products back to the reactor for further propylene oxide addition, and adjusting the reactor temperature among other means.

The monopropylene glycol methyl ether family includes two isomers, 1-methoxy-2-propanol (PM2) and 2-methoxy-1-propanol (PM1). Using industry standard base-catalyzed technology, the PM2/PM1 ratio is ˜20/1. Reaction technology giving a selectivity >20/1 is preferable since PM1 is classified as a teratogen and can be present as a component in the commercial PM2 product at <0.5 wt %. In order to achieve this specification, costly distillation is used to separate these similar boiling materials (PM2 bp=118-119° C.; PM1 bp=130° C.).

Catalytically propoxylating PM1 to propoxylated adducts with very little reaction of PM2 can provide a mixture that is easily separated by simple distillation yet retains the highly desired PM2 product. Moreover, a catalyst system that selectively propoxylates methanol to monopropylene glycol methyl ether and at the same time further catalyzes the selective propoxylation of the undesired PM1 product to DPM can result in a highly selective process for producing PM2.

Although the primary hydroxyl group of PM1 is more acidic than the secondary hydroxyl group of PM2, significant propoxylation of both PM1 and PM2 occurs under base-catalyzed (e.g., NaOH or KOH) conditions.

Therefore, a process in which a Schiff base metal complex is used to selectively catalyze PM1 propoxylation to DPM in the presence of PM2 with very little reaction of PM2 would be desirable. Further, a process which yields very little PM1 by performing selective reaction of methanol with propylene oxide over a Schiff base metal complex catalyst followed by further selective reaction of the undesired PM1 product to DPM over the same Schiff base catalyst would also be desirable. Additionally, novel compositions which can be used as catalysts for the regio selective methanolysis of propylene oxide would also be desirable.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the invention, there is provided a composition comprising, consisting of, or consisting essentially of:

an achiral tetradentate Schiff-base metal complex, wherein a monomer of said

Schiff-base metal complex is defined by the formula

wherein R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ comprise, independently of one another, substituents selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, alkynyl, hydrocarbyl, hydroxyl, amino, nitro, alkoxyl, amide, phosphoryl, phosphonate, phosphine, carbonyl, carboxyl, silyl, ether, thioether, sulfonyl, selenoether, ketone, aldehyde, and ester; or wherein two or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ together form a ring selected from the group consisting of a carbocyclic ring and a heterocyclic ring, said ring having from 4 to 10 atoms in the ring; wherein R₅ group is selected from the group comprising a carbon-carbon bond, a methylene group, an ethylene group, an amine group, an oxygen atom, and a sulfur atom; wherein one or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ are capable of providing a complementary interaction to form a component selected from the group consisting of an oligomer, a polymer, and a copolymer; wherein M^(t+) is a Group 2-15 metal capable of complexing with a ligand to affect catalysis, wherein t is an integer between 2 and 4; wherein the group A is selected from the group consisting of neutral groups, bound anionic groups, unbound anionic groups, and combinations thereof, wherein s is the number of A groups associated to the metal and is an integer between 0 and 2; and wherein said composition is selected from the group consisting of oligomer, polymer, and copolymer.

In accordance with another embodiment of the present invention, there is provided a composition comprising, consisting of, or consisting essentially of a racemic or non-racemic mixture of chiral Schiff base monomers wherein a monomer is defined by formula (I) wherein R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ comprise, independently of one another, substituents selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, alkynyl, hydrocarbyl, hydroxyl, alkoxyl, amino, nitro, amide, phosphoryl, phosphonate, phosphine, carbonyl, carboxyl, silyl, ether, thioether, sulfonyl, selenoether, ketone, aldehyde, and ester;

or wherein two or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ together form a ring selected from the group consisting of a carbocyclic ring and a heterocyclic ring, said ring having from 4 to 10 atoms in the ring; wherein R₅ group is selected from the group comprising a carbon-carbon bond, a methylene group, an ethylene group, an amine, an oxygen atom, and a sulfur atom; wherein one or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ are capable of providing a complementary interaction to form a component selected from the group consisting of oligomer, polymer, and copolymer; wherein M^(t+) is a Group 2-15 metal capable of complexing with a ligand to affect catalysis, wherein t is an integer between 2 and 4; wherein A is selected from the group consisting of neutral groups, bound anionic groups, unbound anionic groups and combinations thereof, wherein s is the number of A groups associated with the metal and is an integer between 0 and 2; and wherein said composition is a diastereomeric mixture of components selected from the group consisting of oligomers, polymers, co-polymers, and combinations thereof.

In accordance with an embodiment of the invention, a process is provided, the process comprising, consisting of, or consisting essentially of contacting an alkylene oxide with 2-methoxy-1-propanol (PM1) in the presence of a catalyst comprising a tetradentate Schiff-base metal complex in a reaction zone under reaction conditions to produce a reaction product, said reaction product comprising alkoxylated PM1 with less than 10 alkylene oxide equivalents.

In accordance with another embodiment of the invention, there is provided a process comprising, consisting of, or consisting essentially of contacting an alkylene oxide with an alcohol in the presence of a catalyst comprising a tetradentate Schiff base metal complex in a reaction zone under reaction conditions to produce a reaction product comprising a mixture of at least two components selected from the group consisting of mono-alkoxylated alcohol, di-alkoxylated alcohol, tri-alkoxylated alcohol, and heavy molecular weight alkoxylated alcohols containing not more than 10 alkylene oxide equivalents.

DETAILED DESCRIPTION OF THE INVENTION

“Chiral” describes an object that is non-superimposable on its mirror image.

“Achiral” describes an object that is superimposable on its mirror image.

“Stereoisomers” are isomeric molecules that have the same molecular formula and sequence of bonded atoms (constitution), but which differ in the three dimensional orientations of their atoms in space.

“Diastereomers” are stereoisomers not related through a reflection operation. They are not mirror images of each other.

“Tetradentate” is a chelating agent which has four groups capable of attachment to a metal ion.

A “Schiff base” is a functional group resulting from the condensation of aldehydes or ketones with primary amines.

A “Lewis acid” is a molecule that is an electron-pair acceptor.

In accordance with an embodiment of the invention, there is provided a composition comprising, consisting of, or consisting essentially of an oligomerized, polymerized or copolymerized achiral tetradentate Schiff-base metal complex. The monomer of the metal complex is defined by formula (I).

R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ comprise, independently of one another, substituents selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, alkynyl, hydrocarbyl, hydroxyl, alkoxyl, nitro, amide, phosphoryl, phosphonate, phosphine, carbonyl, carboxyl, silyl, ether, thioether, sulfonyl, selenoether, ketone, aldehyde, and ester.

In an embodiment, two or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ can together form a ring selected from the group consisting of a carbocyclic ring and a heterocyclic ring, the ring having from 4 to 10 atoms in the ring.

In an embodiment, R₅ is selected from the group comprising a carbon-carbon bond, a methylene group, an ethylene group, an amine, an oxygen atom, and a sulfur atom;

In an embodiment, one or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ are capable of providing a complementary interaction to form a component selected from the group consisting of oligomer, polymer, and copolymer;

A complementary interaction can include: carbon-carbon coupling, condensation, etherification, amide formation, esterification, ring opening polymerizations, olefin metathesis, olefin polymerization such as cationic polymerization, anionic polymerization, radical polymerization, group transfer polymerization, heterogeneous Ziegler-Natta polymerization, and homogeneous Ziegler-Natta polymerization.

M^(t+) is a Group 2-15 metal capable of complexing with a ligand to affect catalysis, wherein t is an integer between 2 and 4;

A is selected from the group consisting of neutral groups, bound anionic groups, unbound anionic groups, and combinations thereof, wherein s is the number of A groups associated to the metal and is an integer between 0 and 2.

The composition can be present as an oligomer, a polymer, or a co-polymer.

In an embodiment of the invention the catalyst is as described in formula II below:

In an embodiment of the invention, M is cobalt and A is selected from the group consisting of carboxylate, sulfonate, halide, alkoxide, hexafluorophosphate, tetrafluoroborate, hexafluoroantimonate and bis(trialkylsilyl)amide. In an embodiment of the invention, A is 3-nitrobenzenesulfonate and s=1.

In an embodiment of the invention, the composition is present as an oligomer bound to a support wherein the oligomer is 1-20 repeat units of the above defined monomer. Examples of supports that can be used include, but are not limited to, an organic polymer, an ion-exchange resin, an inorganic support, a metal organic framework, and carbon. The catalyst can be incorporated into or onto the support by any suitable method known to those skilled in the art including, but not limited to, covalent bonding, ionic bonding, hydrogen bonding, metal complexing, encapsulating, and intercalating.

The following documents provide examples of such supporting techniques and their entire contents are herein disclosed by reference: Baleizo, et. al. Chemical Reviews 2006, 106(9), 3987-4043; Orejón, et al., Industrial and Engineering Chemical Research 2008, 47(21), 8032-8036; Yang, et al., Journal of Catalysis 2007, 248, 204-212; Kim, et. al., Catalysis Today 2000, 63, 537-547.

In an embodiment of the invention, the catalyst can be incorporated into polymeric structures by utilizing any of several different methods. The following documents provide examples of such techniques and their entire contents are herein disclosed by reference. Hu, et al., Journal of Applied Polymer Science 2006, 101, 2431-2436 Song, et al., Tetrahedron Letters 2003, 44, 7081-7085, Kwon, et al., Catalysis Today 2003, 87, 145-151, Gill, et al., Chemistry—A European Journal 2008, 14, 7306-7313, Zheng, et al., Chemistry—A European Journal 2006, 12, 576-583, Zheng, et al., Advanced Synthesis and Catalysis 2008, 350, 255-261.

In an embodiment of the invention, more than one of the composition is present and is joined by a polyfunctional A, wherein A is selected from the group consisting of a polycarboxylate, polysulfonate, and a mixture thereof.

In an embodiment of the invention more than one achiral monomeric composition can be linked with one or more achiral monomers to yield greater catalytic activity than the single monomer. One embodiment of the composition is shown in Formula III below wherein the M^(t+) group(s) independently of one another is(are) a Group 2-15 metal capable of complexing with the ligand to affect catalysis, wherein t=2, 3, or 4; and wherein the group(s) A independently of one another is(are) selected from the group consisting of neutral groups, bound and unbound anionic groups and combinations thereof, where s is the number of A groups associated to the metal and is 0, 1, or 2.

In accordance with an embodiment of the invention, there is provided a composition comprising, consisting of, or consisting essentially of:

A diastereomeric mixture of oligomers, polymers or copolymers of chiral Schiff base monomers, wherein a monomer is defined by formula (I).

The substituents in formula (I) are the same as disclosed above and the composition is a diastereomeric mixture of components selected from the group consisting of oligomers, polymers, co-polymers, and combinations thereof.

One embodiment is described by Formula IV below, wherein the M^(t+) group(s) independently of one another is(are) a Group 2-15 metal capable of complexing with the ligand to affect catalysis, wherein t=2, 3, or 4;

wherein the group(s) A independently of one another is(are) selected from the group consisting of neutral groups, bound or unbound anionic groups, and combinations thereof, where s is the number of A groups associated to the metal and is 0, 1, or 2; and wherein n=1-10 and mixtures thereof.

In an embodiment of the invention, the composition is present as an oligomer bound to a support. ‘Bound’ is defined as covalently bond, ionically bond, hydrogen bonded, metal complexed, encapsulated in a support and intercalated in a support, as described above. The support is selected from the group consisting of an organic polymer, ion-exchange resin, inorganic support, carbon, and mixtures thereof.

In an embodiment of the invention the racemic or non-racemic chiral monomeric composition is present wherein at least two monomeric metal ligand complexes are joined by a polyfunctional A to form a diasteriomeric mixture of molecules comprising more than one chiral monomeric ligand, where A is from a group containing a polycarboxylate (e.g. adipic acid), polysulfonate, and mixtures thereof.

In an embodiment of the invention, there is provided a process comprising, consisting of, or consisting essentially of contacting an alkylene oxide with 2-methoxy-1-propanol (PM1) in the presence of a catalyst comprising a tetradentate Schiff-base metal complex in a reaction zone under reaction conditions to produce a reaction product comprising alkoxylated PM1 with less than 10 alkylene oxide equivalents.

The catalyst is defined as a Schiff-base metal complex, wherein a monomer of the metal complex is defined by Formula (I). The catalyst can be any catalyst described in the previous embodiments, or any other monomeric catalyst defined by Formula (I).

The catalyst can be either homogenous or heterogeneous. The catalyst can be present as a monomer, oligomer, polymer or copolymer as described above. The catalyst can also be bound to a support, as described above.

In an embodiment, a cocatalyst can optionally be used. Generally, the cocatalyst is a Lewis acid. Examples of Lewis acids that can be used include, but are not limited to metal triflate, metal tosylate, tris-perfluoronated aryl borate, metal halides, and combinations thereof. An example of a metal triflate that can be used is aluminum triflate. When a cocatalyst is used, the mole ratio of the catalyst monomeric unit to the co-catalyst is generally in the range of from about 1:1 to about 20:1.

The alkylene oxide is generally selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, pentylene oxide, hexylene oxide, epihalohydrin and combinations thereof. In an embodiment, the alkylene oxide is propylene oxide.

The alkylene oxide and PM1 are generally present in a mole ratio of from about 0.01/1 to about 100/1. In an embodiment the reaction conditions includes a mole ratio of from 0.25/1 to about 10/1

The reaction conditions in the reaction zone generally include a temperature in the range of from about −10° C. to about 200° C. In an embodiment, the reaction conditions include a temperature in the range of from 0° C. to 60° C.

The reaction zone can be of the type comprising of a fixed bed, a fluidized bed, a continuous stirred tank reactor (CSTR), batch, semi-batch, continuous types or combinations thereof. Said reaction zone can be operated for example isothermally, adiabatically, or a combination thereof.

A reaction product is produced which comprises alkoxylated PM1 with less than 10 alkylene oxide equivalents. The reaction product generally comprises unreacted 2-methoxy-1-propanol (PM1), unreacted alkylene oxide, mono-alkoxylates of PM1, di-alkoxylates of PM1, and heavy molecular weight alkoxylates of PM1, which are alkoxylates with 3 to 10 alkylene oxide equivalents. The mono-alkoxylates of PM1 are typically present in the reaction product in an amount in the range of from about 0.1 weight percent to about 100 weight percent, based on the total weight of the reaction product. The di-alkoxylates of PM1 are typically present in the reaction product in an amount in the range of from about 0 weight percent to about 10 weight percent, based on the total weight of the reaction product.

In an embodiment of the invention, there is disclosed a process comprising, consisting of or consisting essentially of contacting an alkylene oxide with an alcohol in the presence of a catalyst comprising a tetradentate Schiff-base metal complex in a reaction zone under reaction conditions to produce a reaction product comprising a mixture of at least two components selected from the group consisting of a mono-alkoxylated alcohol, a di-alkoxylated alcohol, a tri-alkoxylated alcohol, and heavy molecular weight alkoxylated alcohols containing not more than 10 alkylene oxide equivalents.

In an embodiment, the alkoxylated alcohol products from above can optionally be contacted with additional alkylene oxide in the presence of the catalyst in a reaction zone under reaction conditions to produce a second reaction product with a mono-alkoxylated alcohol/di-alkoxylated alcohol product ratio less than in the first reaction product.

The catalyst is defined as an achiral or chiral tetradentate Schiff-base metal complex, wherein a monomer of said metal complex is defined by Formula (I). The catalyst can be any composition described in the above embodiments, or any other suitable composition defined by Formula (I) including monomeric forms.

The catalyst can be either homogenous or heterogeneous. The catalyst can be present as a monomer, an oligomer, a polymer or mixture thereof. The catalyst can also be bound to a support, as described above.

In an embodiment, a cocatalyst can also be used. The cocatalyst is a Lewis acid. Examples of Lewis acids that can be used include, but are not limited to metal triflate, metal tosylate, tris-perfluorinated aryl borate, metal halides, alkyl metals and combinations thereof. When a cocatalyst is used, the ratio of the catalyst monomer unit to the cocatalyst is generally in the range of from about 1:1 to about 20:1. In an embodiment, the Lewis acid is aluminum triflate.

Generally, alkylene oxide is selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, pentylene oxide, hexylene oxide, epihalohydrin and combinations thereof. In an embodiment, the alkylene oxide is propylene oxide.

Generally, the alcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, pentanol, hexanol, 2-ethylhexanol, propylene glycol, ethylene glycol, glycerol, erythritol, pentaerythritol, trimethylolpropane, sorbitol, 2-methoxy-1-propanol, 1-methoxy-2-propanol, glycol ether, phenol and combinations thereof. In an embodiment, the alcohol is methanol.

In this embodiment, alkylene oxide and the alcohol are typically present in a ratio of from about 0.1/1 to about 10/1.

The reaction conditions in the reaction zone generally include a temperature in the range of from about −10° C. to about 200° C. In an embodiment, reaction conditions can include a temperature in the range of from 0° C. to 60° C.

The reaction zone can be of the type comprising of fixed bed, fluidized bed, continuous stirred tank reactor (CSTR), batch reactor, semi-batch reactor, continuous reactor or combination of thereof, said reaction zone can be operated for example isothermally, adiabatically, or a combination thereof.

The reaction zone of the optional secondary reaction step in this embodiment can be in either the same or different vessels as the reaction zone of the first reaction step.

A reaction product is produced which comprises alkoxylated alcohols with less than 10 alkylene oxide equivalents. The reaction product of the first and second reaction zones comprises at least two of monoalkoxylated alcohols (MA), dialkoxylated alcohols (DA), trialkoxylated alcohols (TA) and heavy molecular weight alkoxyated alcohols containing less than 10 alkylene oxide equivalents per molecule. The MA is present in said reaction product in an amount in the range of from about 10 weight percent to about 99.99 weight percent, based on the total weight of said reaction product. The DA is present in said reaction product in an amount in the range of from about 0.01 weight percent to about 80 weight percent, based on the total weight of said reaction product. The TP is present in said reaction product in an amount in the range of from about 0 weight percent to about 1 weight percent, based on the total weight of said reaction product.

The used catalyst can be isolated or concentrated in a process stream and recycled back to the reactor. Prior to recycling the catalyst may optionally be reactivated for example by treatment with acid, a source of oxygen, a metal capable of electron transfer, or a combination thereof.

EXAMPLES

The following examples are intended to be illustrative of the present invention and to teach one of ordinary skill in the art to make and use the invention. These examples are not intended to limit the invention in any way.

Preparation of Oligomeric-Salen Ligands

Example 1 Preparation of S,S-Cyclohexanediamine Oligomeric Salen Ligand (A) and R,R-Cyclohexanediamine Oligomeric Salen (A′)

Prepared as per procedure described in White, D. E., Harvard University Thesis: “Development and mechanistic studies of a highly active and selective oligomeric (salen)Co(III) catalyst for asymmetric epoxide ring opening reactions” 2005, pp. 169-174.

Example 2 Preparation of Ethylenediamine Oligomeric Salen Ligand (B)

A round bottom flask (100 mL) with a teflon coated stir bar was charged with bis(3-t-butyl-5-formyl-4-hydroxyphenyl) heptanedioate (0.40 g, 0.78 mmol, synthesized as per procedure provided by White, D. E., Harvard University Thesis: “Development and mechanistic studies of a highly active and selective oligomeric (salen)Co(III) catalyst for asymmetric epoxide ring opening reactions” 2005, p. 172), ethane-1,2-diamine (0.047 g, 0.78 mmol) and benzene (50 mL). The round bottom flask was equipped with a Dean-Stark trap and a cold water condenser. The reaction was placed under a N₂ atmosphere and was refluxed for 18 hours. The reaction mixture was diluted with diethyl ether (50 mL) and washed with deionized water (50 mL). The organic layer was dried over MgSO₄, filtered and upon rotary evporation and further drying in vacuo (50° C.), afforded 330 mg (39% yield) of yellow/orange solids.

Example 3 Preparation of Phenylenediamine Oligomeric Salen Ligand (C)

A round bottom flask (100 mL) with a Teflon coated stir bar was charged with bis(3-t-butyl-5-formyl-4-hydroxyphenyl) heptanedioate (0.40 g, 0.78 mmol, synthesized as per procedure provided by White, D. E., Harvard University Thesis: “Development and mechanistic studies of a highly active and selective oligomeric (salen)Co(III) catalyst for asymmetric epoxide ring opening reactions” 2005, p. 172), benzene-1,2-diamine (0.048 g, 0.44 mmol) and benzene (50 mL). p-Toluene sulfonic acid (PTSA, 0.035 g, 0.19 mmol) was added into the reaction mixture and the round bottom flask was equipped with a Dean-Stark trap and a cold water condenser. The reaction was placed under a N₂ atmosphere, stirred magnetically and refluxed overnight. The following morning an aliquot of the reaction mixture was concentrated to dryness and dissolved in CDCl₃ for ¹H NMR analysis which showed near complete consumption of the starting dialdehyde. The undissolved PTSA was filtered and the benzene solution was washed with d.i. water and dried over MgSO₄. Filtration, removal of solvent by rotary evaporation and in vacuo drying afforded 0.43 g (94%) of orange solids.

Example 4 Preparation of Diasteriomeric Trans-Diaminocyclohexane Oligomeric Salen (D)

A round bottom flask (250 mL) was equipped with a Teflon coated stir bar and charged with Bis(3-t-butyl-5-formyl-4-hydroxyphenyl) heptanedioate (0.512 g, 0.999 mmol, synthesized as per procedure provided by White, D. E., Harvard University Thesis: “Development and mechanistic studies of a highly active and selective oligomeric (salen)Co(III) catalyst for asymmetric epoxide ring opening reactions” 2005, p. 172), trans-diaminocyclohexane (0.114 g, 0.999 mmol) and benzene (75 mL). The reaction was heated to 50° C. for 1.5 hours and checked for progression by HPLC at which time no remaining free dialdehyde was detected. The round bottom flask was fitted with a Dean-Stark trap and the reaction was refluxed for 8 hours overnight. An aliquot of the reaction mixture was diluted in fresh benzene and analyzed by HPLC showing two unresolved peaks at 21.715 and 21.751 minutes by evaporative light scattering detector. The reaction mixture was diluted with ethyl acetate (30 mL) and loaded into a separation funnel. The organic mixture was washed successively with d.i. water and brine. Upon phase separation, the organic layer was dried over Mg50₄, filtered and concentrated to dryness by rotary evaporation followed by in vacuo drying. By ¹H NMR, it was determined that benzene was present in the product so the solids were dissolved in methylene chloride and concentrated by rotary evaporation twice and finally dried in vacuo, thus yielding yellow/brown crystalline solid 0.580 g (98%).

Example 5 General Preparation of Salen-Cobalt Complexes

Co(II) acetate tetrahydrate (0.036 g, 0.14 mmol) was made into a solution with 2 mL of methanol in an inert atmosphere box. This solution was added to a toluene (3 mL) solution of the salen ligand (0.083 mmol) and allowed to stir under anaerobic conditions for 1.5 h. The mixture was concentrated under vacuum leaving a brick red solid residue. To this was added 0.083 mmol of organic acid (3-nitrobenzenesulfonic acid*1H₂O, toluenesulfonic acid, or acetic acid) and the mixture was taken up into 10 mL of methylenechloride and 2 mL of toluene. The mixture was removed from the glovebox and allowed to stir open to air overnight. After solvent removal the brownish/green solid was used without further purification (each complex noted as “ligand”-Co(III)-X where X refers to the respective counter ion for the organic acid used in the oxidation, 3-nitrobenzenesulfonate (SNOBS), p-toluenesulfonate (OTs), or acetate (OAc)).

Example 6 General Epoxide Ring Opening Procedure

The Co(III) Salen complex was weighed into a thick-walled vial fitted with a magnetic stir bar. To this was added a pre-mixed mixture of propylene oxide and methanol. The vial was capped and placed into an aluminum block on a stir plate and allowed to stir without added heat. The composition of the reaction mixture was examined by GC. Results for each of the complexes are summarized in the following table:

rac-PO MeOH Catalyst rxn time % PO PM/DPM + (g) (g) (g) (h) conv PM2/PM1 highers 50:50 A-Co(III)-3NOBS/ A′-Co(III)-3NOBS 0.23 0.22 0.003 0.75 100%  370 593 B-Co(III)-3NOBS 0.44 0.87 0.011 4 61% 81 219 C-Co(III)-3NOBS 0.86 0.65 0.012 4 83% 294 184 D-Co(III)-3NOBS 1.36 0.89 0.014 1.5 89% 324 466

Preparation of Si-Supported Monomeric Salen (E)

Example 6 Synthesis of 10-undecenoic acid, 3-tert-butyl-5-formyl-4-hydroxyphenylester (2)

A Schlenk flask equipped with a stir bar was charged with 3-tert-butyl-2,5-dihydroxybenzaldehyde (2.730 g, 14.06 mmol), 10-undecenoic acid (2.590 g, 14.06 mmol) and N,N-dimethylaminopyridine (0.172 g, 1.406 mmol). The flask was purged with N2 and THF (12 mL) and N,N-dimethylformamide (0.6 mL) were added. The mixture was cooled to 0° C. in an ice bath and N,N′-diisopropylcarbodiimide (1.86 mL, 14.76 mmol) was added. The mixture was stirred for 5 minutes at 0° C. then allowed to warm up to room temperature and stir overnight. The precipitated urea was filtered off and the mixture washed with 6 mL. THF was then removed under vacuum. The crude orange liquid was purified by flash chromatography using hexane:ethyl acetate (4:1) to give 4.354 g (86%) of a yellow-orange liquid. ¹H NMR (RT, 500 MHz, C₆D₆): δ=12.09 (s, 1H), 9.08 (s, 1H), 7.30 (d, J_(HH)=5 Hz, 1H), 6.77 (d, J_(HH)=5 Hz, 1H), 5.79 (m, 1H), 5.02 (m, 2H), 2.33 (t, J_(HH)=13 Hz, 2H), 1.99 (m, 2H), 1.65 (m, 2H), 1.37 (s, 9H), 1.35-1.17 (m, 10H). ¹³C NMR (RT, 126 MHz, C₆D₆): δ=196.3, 171.6, 158.9, 143.1, 139.9, 139.1, 123.6, 120.5, 114.6, 35.25, 34.52, 34.30, 29.82, 29.72, 29.57, 29.55, 29.42, 29.27, 29.25, 25.37.

Example 7 Synthesis of 3-tert-butyl-5-formyl-4-hydroxyphenyl-11-(diethoxy(methyl)silyl)-undecanoate (3)

In a 50 mL round-bottomed flask was weighed the olefin-tethered hydroxybenzaldehyde 2 (1.939 g, 5.379 mmol) and diethoxymethylsilane (0.939 g, 6.9924 mmol). Pt₂O (0.009 g, 0.040 mmol) was then added. The flask was equipped with a reflux condenser and the mixture was stirred at 85° C. for 20 hrs. After reaction, the mixture was taken up in anhydrous ethanol (20 mL) and filtered through activated carbon. Volatiles were then removed in vacuo to give 2.541 g (96%) of a yellow-orange oily liquid as a single regioisomer. Note: previous attempts at synthesizing 3 using stoichiometric amounts of diethoxymethylsilane led to small amounts of unreacted starting olefinic material. ¹H NMR (RT, 500 MHz, C₆D₆): δ=12.12 (s, 1H), 9.06 (s, 1H), 7.31 (s, 1H), 6.76 (s, 1H), 3.71 (q, J_(HH)=7 Hz, 4H), 2.33 (t, J_(HH)=7.5 Hz, 2H), 1.67 (m, 2H), 1.53 (m, 2H), 1.37 (s, 9H), 1.35-1.20 (m, 10H), 1.17 (t, J_(HH)=7 Hz, 6H), 0.73 (m, 2H), 0.17 (s, 3H). ¹³C NMR (RT, 126 MHz, C₆D₆): δ=196.3, 171.6, 158.9, 143.1, 139.9, 123.6, 120.5, 58.24, 35.25, 34.53, 33.90, 30.10, 30.07, 29.95, 29.81, 29.62, 29.27, 25.40, 23.64, 18.92, 14.75, −4.28. ²⁹Si NMR (RT, 99 MHz, C₆D₆): δ=−5.97 (s).

Example 8 Synthesis of 3-tert-butyl-5-((E)-((1R,2R)-2-((E)-3,5-di-tert-butyl-2-hydroxybenzylideneamino)-cyclohexylimino)methyl)-4-hydroxyphenyl-11-(diethoxy(methyl)-silyl)undecanoate (5)

In a two-necked 250 mL flask was placed 1R,2R-diaminocyclohexane monohydrochloride (0.255 g, 1.693 mmol), 3,5-di-tert-butyl-2-hydroxybenzaldehyde (0.397 g, 1.693 mmol) and 4 Å molecular sieves (0.166 g). The flask was placed under a nitrogen atmosphere and anhydrous ethanol (10 mL) was syringed in to give a yellow mixture. The mixture was allowed to stir overnight. ¹H NMR of an aliquot confirmed that the reaction proceeded (with only ca. 3% of the starting aldehyde remaining). Tethered benzaldehyde 3 (0.397 g, 1.693 mmol) was dissolved in 6 mL of CH₂Cl₂ and syringed into the reaction flask. NEt₃ (0.47 mL, 3.385 mmol) was then syringed dropwise over 5 min. The mixture was allowed to stir overnight under nitrogen. The reaction was then filtered through a pad of silica gel on a glass frit and washed with CH₂Cl₂. The filtrate was rotovaped to give a yellow oily residue, which was purified by flash chromatography (95% hexane: 5% ethyl acetate; R_(f)=0.15) to give a bright yellow oil (0.931 g, 68%). ¹H NMR (RT, 300 MHz, C₆D₆): δ=14.15 (s, 1H), 13.96 (s, 1H), 7.90 (s, 1H), 7.72 (s, 1H), 7.48 (d, J_(HH)=2.5 Hz, 1H), 7.19 (d, J_(HH)=2.5 Hz, 1H), 6.95 (d, J_(HH)=2.5 Hz, 1H), 6.81 (d, J_(HH)=2.5 Hz, 1H), 3.71 (q, J_(HH)=7 Hz, 4H), 2.84 (m, 2H), 2.32 (t, J_(HH)=7.5 Hz, 2H), 1.70-1.21 (m, 24H), 1.60 (s, 9H), 1.48 (s, 9H), 1.26 (s, 9H), 1.17 (t, J_(HH)=7 Hz, 6H), 0.72 (m, 2H), 0.17 (s, 3H). ¹³C NMR (RT, 76 MHz, C₆D₆): δ=171.7, 166.5, 165.4, 158.6, 158.3, 142.6, 140.2, 138.7, 136.8, 127.1, 126.4, 123.3, 122.1, 118.6, 118.4, 72.17, 71.88, 58.21, 35.46, 35.26, 34.61, 34.32, 33.90, 33.09, 33.04, 31.76, 30.09, 30.06, 29.93, 29.88, 29.82, 29.62, 29.49, 25.44, 24.46, 23.61, 18.89, 14.69, −4.33.

Example 9 Supporting the Monomeric Salen Ligand on Silica (E)

In a 50 mL flask was placed amorphous silica gel (0.320 g; 200 m²/g, fully hydroxylated; previously activated in a 100° C. vacuum oven for 20 hrs). Monomeric salen ligand 5 (2.31 mL; as a 0.0411 M solution in 2:1 CH₂Cl₂/DMF, 0.095 mmol) was syringed on top of the silica. The sides of the flask were rinsed with 1 mL CH₂Cl₂ and the slurry was stirred under nitrogen at room temperature for 30 min. Vacuum was applied on the mixture to evaporate CH₂Cl₂ and most of the DMF, after which the flask was placed in a 100° C. oil bath under vacuum for overnight stirring under full vacuum. After 20 hrs, the contents of the flask were rinsed with CH₂Cl₂ and filtered through a glass frit, with sequential washes of CH₂Cl₂, MeOH and CH₂Cl₂. The solid was collected into a vial and dried in a vacuum oven at 50° C. for 48 hrs to give a bright yellow powder (0.345 g). The yellow filtrate was concentrated in vacuo to yield 0.034 g of a yellow oil, E; ligand concentration based on weight difference is calculated as 157 μmol/g_(solid). Thermogravimetric analysis of a sample revealed a ligand concentration of 149 μmol/g_(solid). Elem. anal. found (%): C, 7.1; N, 0.38. C/N wt % ratio calcd. for C₄₄H₆₈N₂O₆Si: 18.86. Found: 18.68.

Example 10 Preparing Silica-Supported Monomeric Cobalt(III)-Salen Complex (E-Co(III)-3NOBS)

In a nitrogen-purged glovebox, a vial was charged with silica-supported ligand E (0.055 g, 0.008 mmol ligand) and a stir bar. In a separate vial, Co(OAc)₂.4H₂O (0.003 g, 0.011 mmol) was dissolved in 3 mL of MeOH/toluene (1:1) to give a pink solution, which was then added to the supported ligand and allowed to stir for 30 min. The mixture immediately turned orange-red. The red mixture was filtered through a glass fit and washed with MeOH and CH₂Cl₂. The solid was then placed in a vial and 3-NO₂—C₆H₄SO₃H.xH₂O where x is approximately 1 (0.002 g, 0.009 mmol) was added as a suspension in CH₂Cl₂. The resulting mixture, which turned dark green, was allowed to stir overnight. After evaporation of the volatiles, the remaining green solid was rinsed and washed copiously with MeOH and CH₂Cl₂, before being dried in a vacuum oven.

Preparation of Si-Supported Dimeric Salen (F)

Example 11 Synthesis of bis(3-tert-butyl-5-formyl-4-hydroxyphenyl) heptanedioate (6)

A Schlenk flask equipped with a stir bar was charged with 3-tert-butyl-2,5-dihydroxybenzaldehyde (1.075 g, 5.535 mmol), pimelic acid (0.443 g, 2.767 mmol) and N,N-dimethylaminopyridine (0.068 g, 0.5535 mmol). The flask was purged with nitrogen and THF (4.7 mL) and N,N-dimethylformamide (0.2 mL) were added. The mixture was cooled to 0° C. in an ice bath and N,N′-diisopropylcarbodiimide (0.9 mL, 5.811 mmol) was added. The mixture was stirred for 5 minutes at 0° C. then allowed to warm up to room temperature and stir overnight. The precipitated urea was filtered off and the mixture washed with 6 mL THF. Volatiles were then removed under vacuum. The crude red oil was purified by flash chromatography using hexane/ethyl acetate (5:1) to give 1.108 g (78%) of a red oil. ¹H NMR (RT, 500 MHz, C₆D₆): δ=12.10 (s, 2H), 9.08 (s, 2H), 7.31 (d, J_(HH)=2.5 Hz, 2H), 6.78 (d, J_(HH)=2.5 Hz, 2H), 2.29 (t, J_(HH)=7 Hz, 4H), 1.60 (5, J_(HH)=7 Hz, 4H), 1.37 (s, 18H), 1.30 (m, 2H).

Example 12 Synthesis of 1-(3-tert-butyl-5-((E)-((1R,2R)-2-((E)-3-tert-butyl-5-(11-(diethoxy(methyl)silyl)undecanoyloxy)-2-hydroxybenzylideneamino) cyclohexylimino)methyl)-4-hydroxyphenyl) 7-(3-tert-butyl-5-((E)-((1R,2R)-2-((E)-3-tert-butyl-5-(11-(diethoxy(methyl)silyl)-undecanoyloxy)-2-hydroxybenzylideneamino)cyclohexylimino)methyl)-4-hydroxyphenyl) heptanedioate (8)

In a two-necked 250 mL flask was placed 1R,2R-diaminocyclohexane monohydrochloride (0.112 g, 0.7435 mmol), tethered hydroxybenzaldehyde 3 (0.368 g, 0.7435 mmol) and 4 Å molecular sieves (0.089 g). The flask was placed under a nitrogen atmosphere and anhydrous ethanol (13 mL) was syringed in to give a yellow mixture. The mixture was allowed to stir overnight. ¹H NMR analysis of an aliquot showed the desired intermediate as the major product with ca. 7% starting aldehyde remaining and some double-condensation product formed as well. A solution of bis-benzaldehyde 6 (0.191 g, 0.3717 mmol) in CH₂Cl₂ (6 mL) was syringed into the reaction flask, after which NEt₃ (0.2 mL, 1.487 mmol) was slowly syringed in over 5 minutes. The reaction mixture was allowed to stir further for 18 hrs. After reaction, the dark orange solution was passed through a thin pad of silica on top of a pad of Celite in a glass fritted filter (Note: even with lots of CH₂Cl₂ washes, some material remained on the silica). The filtrate was dried under vacuum to give 0.455 g (74%) of a dark orange-brown oil. Because the crude NMR data showed that the product was >90% pure, no further purification was needed. It was shown in previous attempts that flash chromatography degrades the product further and was thus avoided here. It is also important to note the presence of vinylic species (dehyrosilylation) from olefinic impurities in tethered benzaldehyde 3 (10-15% by NMR). ¹H NMR (RT, 500 MHz, C₆D₆): δ=14.04 (s, 4H), 7.76 (s, 2H), 7.75 (s, 2H), 7.19 (d, J_(HH)=2.5 Hz, 4H), 6.86 (d, J_(HH)=2.5 Hz, 4H), 5.78 (m, vinylic impurity), 5.01 (m, vinylic impurity), 3.70 (q, J_(HH)=7 Hz, 8H), 2.81 (m, 4H), 2.33 (t, J_(HH)=7 Hz, 4H), 2.28 (t, J_(HH)=7 Hz, 4H), 1.71-1.06 (m, 54H), 1.48 (s, 18H), 1.47 (s, 18H), 1.16 (t, J_(HH)=7 Hz, 12H), 0.70 (m, 4H), 0.15 (s, 6H). ¹³C NMR (RT, 126 MHz, C₆D₆): δ=171.5, 171.3, 165.1, 165.1, 158.1, 158.0, 142.4, 142.4, 138.6, 138.5, 123.1, 121.8, 121.8, 118.3, 71.62, 71.55, 57.83, 34.88, 34.86, 34.21, 33.88, 33.45, 32.47, 29.66, 29.63, 29.49, 29.38, 29.19, 29.18, 29.10, 28.44, 25.01, 24.51, 23.94, 23.16, 18.45, 14.25, −4.80.

Example 13 Supporting Dimeric Ligand 8 on Silica (F)

In a 250 mL flask was placed amorphous silica gel (0.494 g; 200 m²/g, fully hydroxylated; previously activated in a 100° C. vacuum oven for 20 hrs). Dimeric salen ligand 8 (13.3 mL; as a 0.01098 M solution in CH₂Cl₂) was syringed on top of the silica. DMF was then added (6.5 mL). The slurry was stirred under N₂ at RT for 1 hr. Volatiles were then evaporated, after which the flask was placed in a 100° C. oil bath under full vacuum for overnight drying. The contents of the flask were rinsed with CH₂Cl₂ and filtered through a glass frit, with sequential washes of CH₂Cl₂, MeOH and CH₂Cl₂. The resulting yellow solid was dried in a vacuum oven at 55° C. for 24 hrs. Yield: 0.586 g. The yellow filtrate was concentrated in vacuo to yield 0.061 g of a yellow oil; ligand concentration based on weight difference is calculated as 111 μmol/g_(solid), corresponding to 222 μmol/g for potential cobalt sites. Thermogravimetric analysis of a sample revealed a ligand concentration of 149 μmol/g_(solid), corresponding to 298 μmol/g for potential cobalt sites.

Example 14 Preparing Silica-Supported Dimeric Cobalt(III)-Salen Complex (F-Co(III)-3NOBS)

In a nitrogen-purged glovebox, a vial was charged with (F) (0.349 g, 0.009 mmol ligand) and a stir bar. In a separate vial, Co(OAc)₂.4H₂O (0.009 g, 0.035 mmol) was dissolved in 3 mL of MeOH/toluene (1:1) to give a pink solution, which was then added to the supported ligand and allowed to stir for 30 min. The mixture immediately turned orange-red. The red mixture was filtered through a glass frit and washed with MeOH and CH₂Cl₂. The solid was then placed in a vial and 3-NO₂—C₆H₄SO₃H.xH₂O where x is approxiamately 1 (0.004 g, 0.019 mmol) was added as a suspension in CH₂Cl₂. The resulting mixture, which turned dark green, was allowed to stir overnight.

After evaporation of the volatiles, the remaining green solid was rinsed and washed copiously with MeOH and CH₂Cl₂, before being dried in a vacuum oven.

Example 15 Synthesis of the Trans-Dimeric Ligand (9)

In a two-necked 250 mL flask was placed trans-1,2-diaminocyclohexane monohydrochloride (0.500 g, 3.3190 mmol), the hydrosilylated tethered hydroxybenzaldehyde, 3, (1.642 g, 3.3190 mmol) and 4 Å molecular sieves (0.365 g). The flask was placed under a nitrogen atmosphere and anhydrous ethanol (25 mL) was syringed in to give a yellow mixture. The mixture was allowed to stir overnight. ¹H NMR analysis of an aliquot showed the desired intermediate as the major product. A solution of the bis-hydroxybenzaldehyde, 6, (0.851 g, 1.660 mmol) in CH₂Cl₂ (10 mL) was syringed into the reaction flask, after which triethylamine (0.925 mL, 6.638 mmol) was slowly syringed in over 5 min. The reaction mixture was allowed to stir further for 18 hrs. After reaction, ¹H and ¹³C NMR of an aliquot suggested the desired ligand was the major product of the reaction. The dark orange solution was passed through a thin pad of silica on top of a pad of Celite in a glass frit. The filtrate was roto-evaporated to give 2.578 g (94%) of a dark orange-brown oil. No further purification was necessary.

¹H NMR (RT, 500 MHz, C₆D₆): δ=14.08 (s, 4H), 7.77 (s, 2H), 7.75 (s, 2H), 7.21 (d, J_(HH)=2.5 Hz, 4H), 6.87 (d, J_(HH)=2.5 Hz, 4H), 3.71 (q, J_(HH)=7 Hz, 8H), 2.80 (m, 4H), 2.34 (t, J_(HH)=7 Hz, 4H), 2.28 (t, J_(HH)=7 Hz, 4H), 1.73-1.06 (m, 54H), 1.49 (s, 36H), 1.17 (t, J_(HH)=7 Hz, 12H), 0.71 (m, 4H), 0.17 (s, 6H). ¹³C NMR (RT, 126 MHz, C₆D₆): δ=171.8, 171.6, 165.4, 165.4, 158.4, 158.3, 142.7, 142.6, 138.9, 138.8, 123.4, 122.1, 122.0, 118.6, 71.88, 71.87, 71.83, 58.11, 35.15, 35.13, 34.49, 34.15, 33.73, 32.72, 29.94 29.89, 29.77, 29.66, 29.47, 29.35, 28.71, 25.29, 24.78, 24.19, 23.44, 18.71, 14.53, −4.53.

Example 16 Supporting Trans-Dimeric Ligand (9) on Silica (G)

In a 250 mL flask was placed amorphous silica gel (0.846 g; 200 m²/g, fully hydroxylated; previously activated in a 100° C. vacuum oven for 20 hrs). The trans-dimeric salen ligand, 9, (4.1 mL; as a 0.06143 M solution in CH₂Cl₂) was syringed on top of the silica. DMF was then added (2 mL). The slurry was stirred under N₂ at room temperature for 1 hr. Volatiles were then evaporated, after which the flask was placed in a 100° C. oil bath under full vacuum for overnight drying. The contents of the flask were rinsed with CH₂Cl₂ and filtered through a glass frit, with sequential washes of CH₂Cl₂, MeOH and CH₂Cl₂. The resulting yellow solid was dried in a vacuum oven at 55° C. for 24 hrs. Yield: 1.075 g. The yellow filtrate was concentrated in vacuo to yield 0.142 g of a yellow oil; ligand concentration based on weight difference is calculated as 158 μmol/g_(soild), corresponding to 316 μmol/g for potential cobalt sites. Thermogravimetric analysis of a sample revealed a ligand concentration of 149 μmol/g_(solid), corresponding to 298 μmol/g for potential cobalt sites.

Example 17 Preparing Silica-Supported Trans-Dimeric Cobalt(III)-Salen Complex (G-Co(III)-3NOBS)

In a nitrogen-purged glovebox, a vial was charged with G (0.600 g, 0.089 mmol ligand) and a stir bar. In a separate vial, Co(OAc)₂.4H₂O (0.084 g, 0.3362 mmol) was dissolved in 3 mL of MeOH/toluene (1:1) to give a pink solution, which was then added to the supported ligand and allowed to stir for 60 min. The mixture immediately turned orange-red. The red mixture was filtered through a glass frit and washed with MeOH and CH₂Cl₂. The solid was then placed in a vial and 3-NO₂—C₆H₄SO₃H.xH₂O (where x is approximately 1) (0.041 g, 0.1849 mmol) was added as a suspension in CH₂Cl₂. The resulting mixture, which turned dark green, was allowed to stir overnight. After evaporation of the volatiles, the remaining green solid was rinsed and washed copiously with MeOH and CH₂Cl₂, before being dried in a vacuum oven.

Example 18 Methanolysis of Propylene Oxide Using Silica Supported Salen Complexes

In a thick-walled vial equipped with a stir bar was added the silica supported cobalt salen catalyst. Anhydrous methanol was then added to the vial via syringe, followed by addition of propylene oxide in a 2:1 molar ratio, respectively. The vial was capped and the brown mixture was allowed to stir vigorously at room temperature for the indicated amount of time. Propylene oxide conversion and product distribution was obtained by GC. Note: S-propylene oxide was used with complexes E-Co(III)-3NOBS and F-Co(III)-3NOBS, but racemic propylene oxide was used with complex G-Co(III)-3NOBS. The results are summarized in the following table:

Rxn PO Catalyst Loading time Conversion PM2/ Complex (mol % WRT PO) (h) (%) PM1 E-Co(III)-3NOBS 0.02 1.5 85% 432 F-Co(III)-3NOBS 0.05  0.75 97% 1054  G-Co(III)-3NOBS 0.05 2.8 96% 252 Conditions: 2:1 MeOH/PO mol ratio, room temperature, S-PO was used for E & F and rac-PO was used for G

Example 19

A thick-walled vial was charged with a 50:50 mixture of Co(III) metal complex from Examples 9a and 9b (0.0141 grams, 0.0176 mmol based on a molecular weight of 801-one cobalt Schiff base monomer) and 0.001 grams of aluminum triflate. A solution of 0.428 grams (0.0133 mol) of methanol and 1.551 grams (0.0269 mol) of propylene oxide was added to the vial hosting the catalyst mixture. The vial was immediately sealed and the reaction mixture was stirred at room temperature for 2 hours. A GC analysis of the resultant solution indicated 100% methanol conversion and 54% propylene oxide conversion. The product comprised 84.7 wt % PM2, 0.61 wt % PM1, and 13.55 wt % dipropyleneglycol monomethyl ether isomer mixture.

Example 20

R-propylene oxide (0.927 g, 0.016 mol) and methanol (0.402 gram, 0.0126 mol) were added to a thick-walled vial charged with 0.0107 gram of A-Co(III)-3NOBS. The vial was immediately sealed. An initial exotherm was observed; however, no external heat was added and the mixture was stirred at ambient temperature. Samples of the reaction mixture were taken at 45 minutes and at 2 hours and GC analysis was completed. After 2 hours of stirring at ambient temperature, heat was applied and the mixture was stirred for an additional 2 hours at 78° C. at which time a sample was taken and analyzed by GC. These results are shown in the table below.

Ex. 20 Conversion of Methanol and Propylene Oxide

0.75 h (rt) 2 h (rt) 2 h (rt) 2 h (78 C.) % MEOH conv.   95%   100%   100% % PO conv. 69.40% 75.70% 79.30% PM 2 97.36% 97.20% 95.80% PM 1  0.22%  0.20%  0.22% DPM  0.66%  0.94%  2.25% PM2/PM1 443 486 435

Example 21

R-propylene oxide (1.5874 grams, 0.0274 mol) and methanol (0.4269 gram, 0.0133 mol) were added to a thick-walled vial charged with 0.013 g of A-Co(III)-3NOBS. The vial was immediately sealed. An initial exotherm was observed; however, no external heat was added and the mixture was stirred at ambient temperature. After 2 hours a sample was analyzed by GC for composition (see table below).

Ex. 21 Alkoxylation Products

wt % PM 2 96.20% PM 1  0.12% DPM  1.50% PM2/PM1 802

Example 22

R-propylene oxide (1.33 grams, 0.0231 mol) and methanol (0.75 gram, 0.0234 mol) were made added to a thick-walled vial charged with 0.010 gram of A-Co(III)-3NOBS. The vial was immediately sealed. An initial exotherm was observed; however, no external heat was added and the mixture was stirred at ambient temperature. After 1.5 hours a sample was analyzed by GC for composition (see below).

Ex. 22 Conversion of Methanol and Propylene Oxide

2 h (rt) % MEOH conv.   93% % PO conv.   95% PM 2   98% PM 1 0.15% DPM 0.46%

Example 23

R-propylene oxide (1.28 grams, 0.0221 mol) and methanol (0.717 gram, 0.0224 mol) were made into a solution and added to a thick-walled vial charged with 0.0103 grams of A-Co(III)-3NOBS. The vial was immediately sealed and placed into an aluminum block preheated to 78° C. After 1.5 hours a sample was analyzed by GC for composition (see table below).

Ex. 23 Conversion of Methanol and Propylene Oxide

2 h (78 C.) % MEOH 82% conversion % PO conversion 85% PM 2 97% PM 1 0.55%   DPM 0.46%   PM2/PM1 177

Example 24

(±)-Propylene oxide (0.9168 gram, 0.0158 mol) and Dowanol® PM (at least 99.5% PM2 isomer) (1.0315 grams, 0.0115 mol) were added to a thick-walled vial charged with 0.0045 grams of A′-Co(III)-3NOBS and 0.0067 grams of A-Co(III)-3NOBS. The vial was immediately sealed. After 3 hours of reaction a sample was taken and analyzed by GC for composition (see the table below).

Ex. 24 Conversion of PM2 and Propylene Oxide

2 h (rt) % PM2 conversion trace % PO conversion trace PO 50.90% PM 46.30% DPM  0.58%

Example 25

R-propylene oxide (0.8273 gram, 0.0143 mol) and a 0.68/1 PM2/PM1 mixture (1.1605 grams, 0.0129 mol) were added to a thick walled vial charged with 0.0147 grams of A′-Co(III)-3NOBS. The vial was immediately sealed. After 30 minutes of reaction a sample was taken and analyzed by GC for composition (Table VI). As a comparison, an Aspen simulation using the known reaction rates of 1-methoxy-2-propanol (PM2) and 2-methoxy-1-propanol (PM1) with propylene oxide using potassium hydroxide catalyst was employed to demonstrate the product mix one would obtain while propoxylating the same 0.68/1 PM2/PM1 mixture.

Ex. 25 Conversion of PM2 and PM1 with PO with Co-Salen vs. with KOH

Co-Salen Catalyst Aspen - KOH (0.74 wt % cat., RT, 30 min) (1000 ppm KOH, 100 C, 1.6 h) Feed (g) Product (g) % Conv Feed (lb) Product (lb) % Conv PO 0.83 0.64 22.89 8300 4966 40.17 PM2 0.44 0.43 2.27 4695 3747.7 20.18 PM1 0.65 0.31 52.31 6905 3393.8 50.85 DPM 0.045 0.56 6301 TPM 0.003 0.008 1246

While this invention has been described in detail for the purpose of illustration, it should not be construed as limited thereby but intended to cover all changes and modifications within the spirit and scope thereof. 

1. A process comprising: a) contacting an alkylene oxide with an alcohol in the presence of a catalyst comprising a tetradentate Schiff base metal complex in a reaction zone under reaction conditions to produce a reaction product comprising a mixture of at least two of monoalkoxylated alcohols, dialkoxylated alcohols, trialkoxylated alcohols, heavy molecular weight alkoxylated alcohols having not more than 10 equivalents of alkylene oxide; and b) contacting an alkoxylated alcohol produced in step a) with alkylene oxide in the presence of a catalyst comprising a tetradentate Schiff base metal complex in a reaction zone under reaction conditions to produce a reaction product.
 2. A process in accordance with claim 1 wherein a monomer of said tetradentate Schiff base metal complex is defined by the formula

wherein R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ comprise, independently of one another, substituents selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, alkynyl, hydrocarbyl, hydroxyl, amino, nitro, amide, phosphoryl, phosphonate, phosphine, carbonyl, carboxyl, silyl, ether, thioether, sulfonyl, selenoether, ketone, aldehyde, and ester; or wherein two or more of R₁, R₂, R₃, R₄, Y₁, Y₂, X₁, X₂, X₃, X₄, X₅, X₆, X₇, and X₈ together form a ring selected from the group consisting of a carbocyclic ring and a heterocyclic ring, said ring having from 4 to 10 atoms in the ring; wherein R₅ is selected from the group comprising a carbon-carbon bond, a methylene group, an ethylene group, an amine, an oxygen atom, and a sulfur atom; wherein M^(t+) is a Group 2-15 metal capable of complexing with a ligand to affect catalysis, wherein t is an integer between 2 and 4; and wherein A is selected from the group consisting of neutral groups, bound anionic groups, unbound anionic groups and combinations thereof, wherein s is the number of A groups associated to the metal and is an integer between 0 and
 2. 3. A process in accordance with claim 2 wherein M is cobalt.
 4. A process in accordance with claim 2 wherein A is selected from the group consisting of carboxylate, sulfonate, halide, alkoxide, hexafluorophosphate, hexafluoroantimonoate, tetrafluoroborate and bis(trialkylsilyl)amide.
 5. A process in accordance with claim 2 wherein said catalyst is present as an oligomer having from 1 to 20 repeat units.
 6. A process in accordance with claim 2 wherein said catalyst is bound to a support.
 7. A process in accordance with claim 1 wherein said alkylene oxide is selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, pentylene oxide, hexylene oxide, epihalohydrin and combinations thereof.
 8. A process in accordance with claim 1 wherein said alcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, pentanol, hexanol, 2-ethylhexyl alcohol, sorbitol, glycerol, erythritol, pentaerythritol, trimethylolpropane, ethylene glycol, propylene glycol, glycol ethers, phenol, and combinations thereof.
 9. A process in accordance with claim 1 wherein said alkylene oxide and said alcohol are in a ratio of from about 0.1/1 to about 10/1.
 10. A process in accordance with claim 1 wherein said reaction conditions include a temperature in the range of from about −10° C. to about 200° C.
 11. A process in accordance with claim 1 further comprising the presence of a cocatalyst selected from the group consisting of a Lewis acid.
 12. A process in accordance with claim 11 wherein said Lewis acid is selected from the group consisting of a metal triflate, metal tosylate, a tris-perfluoronated aryl borate, and combinations thereof.
 13. A process in accordance with claim 11 wherein said cocatalyst is aluminum triflate.
 14. A process in accordance with claim 11 wherein the ratio of said catalyst monomer unit to said cocatalyst is in the range of from about 1:1 to about 20:1.
 15. A process in accordance with claim 1 wherein said reaction zone of step b) is the same vessel as the reaction zone of step a).
 16. A process in accordance with claim 1 wherein said reaction zone of step b) is a different vessel from the reaction zone of step a).
 17. A process in accordance with claim 1 wherein said reaction product comprises at least two of monoalkoxylated alcohols (MA), dialkoxylated alcohols (DA), trialkoxylated alcohols (TA) and heavy molecular weight alkoxyated alcohols containing less than 10 alkylene oxide equivalents per molecule.
 18. A process in accordance with claim 17 wherein said MA is present in said reaction product in an amount in the range of from about 10 weight percent to about 99.99 weight percent, based on the total weight of said reaction product.
 19. A process in accordance with claim 17 wherein said DA is present in said reaction product in an amount in the range of from about 0.01 weight percent to about 80 weight percent, based on the total weight of said reaction product.
 20. A process in accordance with claim 17 wherein said TP is present in said reaction product in an amount in the range of from about 0 weight percent to about 1 weight percent, based on the total weight of said reaction product. 